Abstract:
In present investigation, effect of modulation and machining parameters on deformation level of
the chips produced during modulation assisted machining (MAM) has been studied. It is shown
that disruption in tool-chip contact during modulation assisted machining helps in the formation
of discrete chips. Size and shape of the particles produced in MAM can be controlled by varying
modulation and machining conditions. Particulates of different shapes and sizes ranging from
100 µm to 5 mm with an aspect ratio of ~10 were produced using MAM. The morphology of the
particulates produced was characterized by scanning electron microscope (SEM). Deformation in
chip particulates was investigated using X-Ray diffraction. The crystallite size and internal strain
in particulates were evaluated using Scherrer and Williamson-Hall methods respectively. The
crystallite size of the particulates was found to decrease with decrease in their size, whereas
internal strain in particulates was observed to increase with decrease in their size. Furthermore,
the length of particulates was observed to decrease with an increase in the ratio of frequency of
modulation (fm) to frequency of workpiece rotation (fw). However, the corresponding change in
microstrain and crystallite size was insignificant with change in this ratio.
